EP3812354A1 - Method for manufacturing a thermally insulated prefabricated concrete part - Google Patents

Abstract

The present invention relates to a method for producing a thermally insulated precast concrete part, having at least one concrete layer and an insulating layer, the insulating layer being arranged on the concrete layer.

Description

The present invention relates to the technical field of thermal insulation, in particular the production and use of thermally insulated precast concrete parts.

In particular, the present invention relates to a thermally insulated precast concrete part and its use.

The present invention also relates to a dry building material mix for producing an insulating compound which can be used for the thermal insulation of precast concrete parts, as well as its use and the insulating compound obtainable with the dry building material mix.

Finally, the present invention relates to a method for producing a thermally insulated precast concrete part.

Increasingly, not only ceilings and basements of multi-storey houses as well as single and two-family houses are made of concrete, but also storey and interior walls.

The use of concrete allows the creation of very slim load-bearing structures that have a high load-bearing capacity and strength, which enables, for example, large window openings and a very open design. In addition, exposed concrete façades enrich the possibility of architectural design.

The use of concrete also offers the advantage that individual parts, such as wall and ceiling elements, can be industrially prefabricated under controlled and constant conditions and consequently manufactured with constant quality and installed on the construction site almost regardless of the weather. In addition, consistently high quality in the execution of the concrete parts can be guaranteed. Since concrete is used as a liquid mass, which hardens, unusual shapes and individual plans or wishes can be realized using concrete, and this also on an industrial scale. For these reasons, the use of precast concrete parts or prefabricated concrete components has meanwhile become widespread and is constantly increasing.

By using precast concrete parts, the construction time can also be significantly reduced, which saves costs, since only a few prefabricated parts have to be assembled on site on the construction site.

The problem with the use of concrete or precast concrete parts, however, is that concrete has a thermal conductivity of approx. 2 W / (mK). This means that concrete has significantly better thermal conductivity than, for example, masonry made of solid bricks and concrete parts thus represent excellent thermal bridges, which is undesirable in building construction.

The thermal conductivity of concrete is further improved by the steel reinforcement usually contained in concrete.

The good thermal conductivity of concrete means that buildings or parts of buildings made of concrete must be well insulated in order to meet the legal requirements, in particular the Energy Saving Ordinance (EnEV), and to keep the energy costs for heating and cooling buildings within reasonable limits to keep.

Thermal insulation of buildings is usually carried out by means of thermal insulation composite systems (ETICS), which are made up of a plate-shaped insulation material, a reinforcement layer attached to the outside, consisting of a reinforcement mortar and a reinforcement fabric, and a finishing plaster. The insulation panels are usually based on plastics, in particular rigid polystyrene foams (PS), such as, for example, polystyrene particle foam (EPS), polystyrene extruder foam (XPS) or on the basis of rigid polyurethane foams (PUR). Thermal insulation composite systems based on the aforementioned plastic insulation panels have excellent insulation properties under ideal conditions, but have the disadvantage that they form a vapor barrier and moisture from the masonry cannot be released into the environment, which often leads to the formation of mold and algae.

In addition, the humidity increases the thermal conductivity of the system, which is why the theoretical heat transfer coefficient (U-value) according to EN ISO 6946 is often not achieved in practice. Another disadvantage of such composite thermal insulation systems (ETICS) is that they usually Have a thickness of 10 to 20 cm in order to achieve adequate thermal insulation. However, this is particularly undesirable in the case of concrete walls, which allow a very slim construction with large window and door openings.

For this reason, core-insulated precast concrete parts have been developed in which an insulating layer is provided between two concrete layers, namely an outer and an inner layer, the so-called outer or inner shell. Such insulating layers usually consist of the same plastic materials that are also submitted for thermal insulation composite systems, in particular of polystyrene-based materials such as polystyrene particle foam (EPS), polystyrene extruder foam (XPS), or polyurethane (PUR). The plastic-based insulation panels are applied to an already prefabricated concrete layer, usually the outer shell, of the precast concrete part by cutting the insulation panels and attaching them to the concrete shell using an adhesive. Then either the second shell is also attached to the insulation layer or reinforcement is provided which connects the inner and outer concrete shell, with a cavity or gap remaining between the inner concrete shell and the insulation layer, which is filled with grouting concrete at the construction site. the so-called in-situ concrete, is filled. In this way it is possible to obtain a seamless concrete core inside a prefabricated concrete wall or ceiling.

With the aforementioned double-walled, core-insulated precast concrete parts, it is possible to erect buildings in a short time and in a cost-saving manner. However, the problem is that the plastic-based insulation materials are not permeable to diffusion, but form vapor barriers, which promotes the formation of mold, especially in the event that there are thermal bridges, which can hardly be avoided despite great care in planning and building the building.

In addition, the connection of the plastic-based insulation materials with the mineral concrete poses a major problem during disposal, since concrete and plastic usually cannot be separated and the building rubble has to be disposed of as mixed waste or, if certain polystyrenes are used, also as hazardous waste, which is very cost-intensive. This significantly increases the disposal costs.

In addition, it is foreseeable that in the future the legal requirements with regard to the use of plastic-based insulation materials and their Disposal are further tightened, so that this represents a serious disadvantage for building with concrete or precast concrete parts, which in principle is superior to conventional construction techniques in many respects and also opens up new design options.

In the prior art, no insulation system is known with which thermally insulated, in particular core-insulated, precast concrete elements can be produced, so that not only the use of the precast concrete elements is possible at economically sensible conditions, but also the disposal is uncritical.

The present invention is therefore based on the object of avoiding the aforementioned disadvantages occurring in the prior art, or at least reducing them.

In particular, it is an object of the present invention to provide thermally insulated precast concrete parts which have excellent thermal insulation properties, are harmless from the point of view of the environment and are also easy to dispose of.

In addition, another object of the present invention is to provide a method for producing insulated precast concrete parts which enables a particularly intimate and permanent bond between concrete and insulation.

In addition, another object of the present invention is to provide an insulating material which can be connected very well to concrete, is available as inexpensively as possible to manufacture and has a positive effect on the climate within a building.

The object described above is achieved according to the invention by a precast concrete part according to claim 1; Further advantageous developments and configurations of the precast concrete part according to the invention are the subject of the relevant subclaims.

Another object of the present invention is the use of the precast concrete part according to the invention according to claim 41.

Yet another subject matter of the present invention is a dry building material mix according to claim 42; further advantageous refinements and developments of this aspect of the invention are the subject matter of the relevant subclaims.

The present invention again further provides the use of the dry building material mix according to the invention according to claim 59; further advantageous refinements of this aspect of the invention are the subject of the relevant sub-claim.

The present invention again further provides an insulating compound according to the invention according to claim 61.

Finally, the present invention also provides a method for producing a precast concrete part according to claim 62; further advantageous refinements of this aspect of the invention are the subject matter of the relevant subclaims.

In the context of the present invention, all values or parameters or the like mentioned below can in principle be determined or determined with standardized or standardized or explicitly stated determination methods or with determination methods known per se to the person skilled in the art.

It goes without saying that the special configurations mentioned below, in particular special embodiments or the like, which are only described in connection with one aspect of the invention, also apply accordingly with regard to the other aspects of the invention, without this needing to be explicitly mentioned.

Furthermore, with all of the relative or percentage, in particular weight-related, quantitative information mentioned below, it should be noted that these are to be selected by the person skilled in the art within the scope of the present invention in such a way that the sum of the ingredients, additives or auxiliaries or the like is always 100% or 100% by weight result. However, this goes without saying for the expert.

Having said that, the subject matter of the present invention is explained in more detail below.

The present invention - according to a first aspect of the present invention - is thus a precast concrete part, comprising at least one concrete layer and an insulating layer, the insulating layer being arranged on the concrete layer and the insulating layer being mineral-based, in particular cement-based.

Because, as has now been found, by using mineral-based, in particular cement-based, insulation layers on a concrete layer, a precast concrete part with excellent thermal insulation properties can be produced in an extremely simple manner.

By using mineral-based, especially cement-based insulation layers, a very intimate and permanent bond between the concrete layer and the insulation layer can also be achieved. This is particularly true in the event that the insulation layer contains a cement-based binder, since an insulation compound or mortar, which forms the insulation layer, can be applied to the still liquid concrete of the concrete layer. Due to the similar binder systems of the concrete and insulation layer, a very intimate and cohesive bond is formed between the concrete layer and the insulation layer, so that there is no need for further adhesives or mortar to attach the insulation layer to the concrete layer.

In addition, a mineral-based or cement-based insulation layer is significantly less sensitive to mechanical damage than, for example, the plastic-based insulation boards commonly used.

The use of a mineral-based, in particular cement-based, insulation layer also ensures that the precast concrete elements according to the invention can be disposed of as purely mineral building rubble and do not have to be declared as mixed waste or even hazardous waste, and have to be disposed of at great expense. The use of mineral-based, in particular cement-based, insulation layers prevents substances that are dubious from an environmental or health point of view from being introduced into buildings via the insulation layer.

The precast concrete part according to the invention is open to diffusion due to the mineral-based, in particular cement-based, insulating layer, whereas standard precast concrete parts, which are thermally insulated, usually form vapor barriers due to the plastic materials used and consequently promote the formation of mold if there are thermal bridges.

The precast concrete part according to the invention can be produced with excellent thermal insulation properties with a very small layer thickness, so that very stable and at the same time highly thermally insulating structures, which offer a variety of design options for architects and planners, are accessible. In particular, it is possible to design the concrete layer as an outer shell in the form of exposed concrete, to which the thermal insulation is applied on the inside.

In particular, when using double-walled core-insulated systems, not only aesthetically very appealing results can be achieved, but especially in systems in which a gap or a cavity is provided between the insulation and a concrete inner shell, a concrete wall can be created through the use of in-situ concrete or grouting concrete or concrete ceiling can be obtained with a seamless concrete core.

The precast concrete part according to the invention can be used both for the production of walls and ceilings and in particular enables the provision of core-insulated prefabricated concrete elements for walls and ceilings.

Since the mineral-based, in particular cement-based, insulating layer is preferably applied to the concrete layer in the form of a mortar, in particular an insulating compound, there is also no waste that inevitably arises from the assembly of plastic insulation panels, especially when there are holes for windows or doors or openings in the Precast parts must be left out. The precast concrete part according to the invention can thus be produced in a very resource-saving and cost-effective manner.

In addition, the precast concrete part according to the invention has all the advantages of conventional precast concrete parts, namely that it can be produced under reproducible and specified conditions with constant quality, with adaptation to individual dimensions, e.g. B. window and door openings and other openings of any kind are possible. Also have the invention Due to the reproducible conditions, precast concrete parts have a high degree of dimensional accuracy, ie uncontrolled or uneven shrinkage during the drying process is avoided.

In the context of the present invention, a concrete skill is to be understood as meaning a prefabricated object, in particular an element, made of concrete, which in principle can have any shape and can be constructed with one or more shells or layers. The precast concrete part can contain further layers, such as an insulation layer, but also pipelines or cable ducts.

In the context of the present invention, a concrete layer is to be understood as a part of an object which is made of concrete and has a certain thickness. The layer is usually flat, i.e. designed with main directions of extent in two spatial directions, whereby it does not necessarily have to be almost two-dimensional, but can in principle assume any shape. A layer generally has a thickness of less than 50 cm in the spatial direction under consideration. Also, the layer does not have to be continuous, but can, for. B. be applied interrupted to another substrate or reinforcement.

In the context of the present invention, an insulating layer is to be understood as a layer of an insulating material, in particular of a hardened plaster mortar or an insulating compound, which has a certain thickness, in particular a layer thickness. In the case of the insulation layer, too, it is true that it does not necessarily have to have an almost two-dimensional extension, i.e. H. preferably extends only in two spatial directions, but can also assume irregular or curved shapes.

In the context of the present invention it is usually provided that the insulation layer is arranged indirectly and / or directly, preferably directly, on the concrete layer. In this context, it is preferred if the insulation layer is applied indirectly and / or directly, preferably directly, to the concrete layer. A direct arrangement or application of the insulation layer is to be understood as meaning that the insulation layer makes direct contact with the concrete layer, ie is arranged on or applied to the concrete layer without further intermediate layers. An indirect arrangement or application of the insulation layer on or on the concrete layer means in the context of the present According to the invention, however, that intermediate layers, such as reinforcement layers or diffusion barriers, are arranged between the concrete layer and the insulation layer.

In the context of the present invention, however, it is preferred if the insulation layer is applied directly to the concrete layer, in particular a first concrete layer.

In addition, it is preferred in the context of the present invention if the concrete layer on which the insulation layer is arranged or on which insulation layer is applied is an outer layer, ie. H. forms the outer shell of the precast concrete part, especially when the precast concrete part is double-walled.

In the context of the present invention, it is further preferred if the insulation layer is arranged on the concrete layer without the use of adhesives and / or mortars. In the context of the present invention, in particular through the use of mineral insulating layers or cement-based insulating layers, which have a binder system very similar to the concrete layer, an intimate and preferably cohesive bond between the concrete layer and the insulating layer can be achieved without further measures that increase adhesion. In the context of the present invention, it is preferred if the insulating layer is applied to the concrete layer as an insulating compound, in particular in the form of a mortar. In this way, a full-surface and particularly good adhesion between the concrete layer and the insulation layer is achieved.

In the context of the present invention it is also usually provided that the insulation layer covers at least one surface of the concrete layer, in particular at least in certain areas. In this context it is preferred if the insulating layer covers at least one area of the concrete layer for the most part, preferably covers at least one area of the concrete layer almost over the entire area. In the context of the present invention, it is therefore preferred if the insulating layer covers at least one surface or side of the concrete layer almost over the entire surface; Usually only recesses remain free for connections to other components or for lines or joints etc.

In the context of the present invention it is preferred if the insulating layer consists predominantly of inorganic materials, preferably consists almost entirely or entirely of inorganic materials.

Particularly good results are obtained in the context of the present invention when the insulating layer is at least 90% by weight, in particular 95% by weight, preferably 97% by weight, preferably 98% by weight, based on the insulating layer, of inorganic Materials.

In the context of the present invention, it is therefore preferred if the mineral-based or cement-based insulating layer is as free as possible from organic substances. In this case, the precast concrete part is to be classified with flammability A1 or A2 according to DIN 4102, which significantly reduces the need for further fire protection measures. In addition, due to the low proportion of organic materials, disposal of the precast concrete part according to the invention is also possible after the period of use as purely mineral building rubble.

In the context of the present invention, the concrete layer or the insulation layer preferably contain organic materials only in the form of additives, in particular, for example, as water repellants, leveling agents, pore formers, etc.

In the context of the present invention, it can also be provided that 90 to 100% by weight, in particular 95 to 100% by weight, preferably 97 to 100% by weight, preferably 98 to 100% by weight of the insulating layer, based on the insulation layer, consists of inorganic materials.

In the context of the present invention it is usually provided that the insulation layer contains inorganic fillers, in particular mineral fillers. In this context, it is usually provided that the insulating layer contains inorganic fillers, in particular mineral fillers, in amounts of at least 20% by weight, in particular 40% by weight, preferably 50% by weight, preferably 60% by weight on the insulation layer.

Likewise, it can be provided within the scope of the present invention that the insulating layer contains inorganic fillers, in particular mineral fillers, in amounts of 20 to 80% by weight, in particular 40 to 75% by weight, preferably 50 to 70% by weight, preferably 60 to 70% by weight, based on the insulating layer. It is preferred according to the invention if at least some of the fillers are in the form of lightweight aggregates.

The lightweight aggregates used or used in the context of the present invention are known as such to the person skilled in the art. In the context of the present invention, the term “surcharge” is to be understood in particular as concrete surcharges according to DIN 1045. The aggregates are fillers with grain sizes that are suitable for the respective binder production. For further information on the term "surcharge", reference can be made in particular to RÖMPP Chemielexikon, 10th edition, Georg-Thieme-Verlag, Stuttgart / New York, Volume 1, 1998, pages 419 and 420 , Keyword: "concrete surcharge" as well as the literature referenced there, the respective content of which is hereby fully incorporated by reference. In the context of the present invention, a lightweight aggregate is understood to mean an aggregate with a grain density of at most 2.0 kg / dm ^3. By using lightweight aggregates, the weight of the concrete in particular can be reduced and, at the same time, the thermal insulation properties are significantly improved due to the porous structure of most lightweight aggregates. Particularly good results are obtained when all of the inorganic fillers used have a grain density of at most 2.0 kg / dm ³ . This also applies to inorganic fillers, which are not conventional concrete aggregates.

In the context of the present invention, it has proven useful if the inorganic filler, in particular mineral filler, selected from the group of volcanic rock, perlite, in particular expanded perlite, vermiculite, in particular expanded vermiculite, pumice, foam and expanded glass, expanded clay, expanded slate, Tuff, expanded mica, lava gravel, lava sand, silica aerogels, silica hybrid aerogels and their mixtures. Particularly good results are achieved in this context if the inorganic filler, in particular mineral filler, is selected from the group of perlite, in particular expanded perlite, vermiculite, in particular expanded vermiculite, aerogels, in particular silica aerogels and / or silica hybrid aerogels, and their Mixtures, preferably their mixtures. The aforementioned inorganic fillers or mineral fillers are, in particular, highly porous inorganic materials which have good thermal insulation properties and are non-flammable.

In the context of the present invention, lightweight aggregates are preferably used in combination with other inorganic, in particular mineral, fillers which preferably have a grain density of at most 2.0 kg / dm ³ .

Particularly good results are obtained in the context of the present invention if the insulating layer is a lightweight aggregate selected from the group of volcanic rock, perlite, in particular expanded perlite, vermiculite, in particular expanded vermiculite, pumice, foam and expanded glass, expanded clay, expanded slate, tuff, expanded mica , Lava gravel, lava sand and mixtures thereof, in combination with an inorganic filler in the form of an airgel, in particular a silica airgel and / or silica hybrid airgel. In particular, the insulation layer contains the combination of lightweight aggregate and other inorganic fillers in the form of an airgel in the quantities mentioned above.

In this context, it has proven particularly useful if the insulation layer is a lightweight aggregate selected from the group of perlite, in particular expanded perlite, vermiculite, in particular expanded vermiculite, and mixtures thereof, in combination with an inorganic filler in the form of an airgel, in particular a silica Airgel and / or a silica hybrid airgel. In particular, the combination of lightweight aggregate and airgel enables mineral-based insulation layers with particularly good thermal insulation properties to be achieved.

Silica aerogels are highly porous solids which consist of more than 90% by volume of pores and are usually made up of silicon dioxide or condensed silica. The usually hydrophilic silica aerogels can be hydrophobized, with hydrophobization being achieved in particular by treatment with hydrophobing agents or by the use of organosilanes or siloxanes in the synthesis of the silica aerogels.

In the context of the present invention, a silica hybrid airgel is to be understood as meaning a silica airgel which contains 1 to 20% by weight, in particular 5 to 15% by weight, based on the silica hybrid airgel, of at least one polysaccharide. The polysaccharide is usually selected from starch, gum arabic, xanthan, pectin, agarose, cellulose ethers, in particular pectin and / or xanthan.

The polysaccharides are usually added during the production of the silica hybrid airgel and form an extremely flexible, but at the same time stable matrix, which flexibly connects the individual silica airgel particles with one another and protects them from excessive mechanical loads.

Compared to conventional silica aerogels, silica hybrid aerogels have significantly improved mechanical properties with only slightly impaired thermal insulation properties.

A suitable process for the production of silica hybrid aerogels is described, for example, in S. Zhao, WJ Malfait, A. Demilecamps, Y. Zhang, S. Brunner, L. Huber, P. Tingaut, A. Rigacci, T. Budtova, and MM Koebel, "Strong, Thermally Superinsulating Biopolymer-Silica Airgel Hybrids by Cogelation of Silicic Acid with Pectin ", Angewandte Chemie, 127, 48, 2015, pages 14490 to 14494 .

In the context of the present invention, it is further preferred if the insulation layer has a weight-related ratio of lightweight aggregate to airgel in the range from 15: 1 to 1:10, in particular 10: 1 to 1: 8, preferably 5: 1 to 1: 5 2: 1 to 1: 2, particularly preferably 2: 1 to 1: 1. The use of lightweight aggregates and aerogels in the aforementioned weight-related ratios enables insulation layers to be produced with excellent thermal insulation properties and gives the insulation layer the necessary mechanical resistance.

In the context of the present invention it can also be provided that the insulation layer contains fibers, in particular inorganic, preferably mineral fibers. The use of fibers can further increase the strength and mechanical resistance of the insulation layer. The use of inorganic fibers, in particular mineral inorganic fibers, is preferred in order to impair the combustibility of the precast concrete parts and to enable problem-free disposal.

If the insulating layer has fibers, it has proven useful if the fibers are selected from calcium silicate fibers, glass fibers, wollastonite fibers, carbon fibers, carbon nanotubes and mixtures thereof. It is particularly preferred in the context of the present invention if the fibers are selected from calcium silicate fibers, glass fibers, wollastonite fibers and mixtures thereof.

Particularly good results are obtained when the fibers are calcium silicate fibers.

As far as the amounts in which the compositions can contain the fibers are concerned, this can of course vary within wide ranges. However, it has proven useful if the composition contains the fibers in amounts of 0.1 to 20% by weight, in particular 0.2 to 15% by weight, in particular 0.5 to 12% by weight, preferably 1 to 10 % By weight, based on the composition. Fibers in the aforementioned areas increase the mechanical stability of the insulation layer on the one hand and enable a reduction in the binder, which can reduce the thermal conductivity, and on the other hand increase the resistance to mechanical loads, for example when transporting or installing the precast concrete elements.

According to a preferred embodiment of the present invention, the insulation layer has a cement-based binder. As already stated above, the use of cement-based binders can achieve a particularly good connection to the concrete layer, in particular to the outer shell, of a precast concrete part. According to a preferred embodiment of the present invention, the insulation layer has cement as the binding agent, in particular Portland cement, preferably white cement, preferably quick-release cement, optionally in combination with additives. Particularly good results are obtained in the context of the present invention when the binding agent of the insulation layer is cement, in particular Portland cement, preferably white cement, preferably quick-release cement, in combination with lime, in particular hydraulic lime, and optionally contains additives.

The precast concrete parts according to the invention have particularly good heat-insulating properties, which is due in particular to the insulating layer. The insulating layer usually has a thermal conductivity in the range from 0.025 to 0.050 W / (mK), in particular 0.030 to 0.045 W / (mK), preferably 0.035 to 0.042 W / (mK). Although the insulation layer is mineral-based and preferably cement-based, it has very low thermal conductivities due to the high filler content and the preferably used airgel.

Likewise, within the scope of the present invention it is usually provided that the insulation layer has a water vapor diffusion resistance number µ, determined according to DIN EN ISO 12542, in the range from 2 to 9, in particular 3 to 7, preferably 4 to 6 has. The precast concrete part according to the invention is thus permeable to water vapor, ie water that gets into the precast concrete part can diffuse through the insulation layer and finally be released into the environment after passing through the concrete layer.

As already stated above, the insulation layer is usually mineral-based or cement-based. In general, the insulation layer has a dry bulk density in the range from 125 to 250 kg / m ³ , in particular 140 to 225 kg / m ³ , preferably 150 to 200 kg / m ³ . The insulation layer used according to the invention is therefore relatively light despite the purely or almost purely inorganic components, ie it has only a low density.

In the context of the present invention it is usually provided that the insulation layer has the combustibility A1 or A2 according to DIN 4102.

According to a preferred embodiment of the present invention it is provided that the precast concrete part is a core-insulated precast concrete part. Particularly good results are thus achieved within the scope of the present invention if the precast concrete part according to the invention has two concrete layers, between which an insulating layer is arranged. One concrete layer is usually referred to as the outer shell and can consist of exposed concrete, for example, while the other concrete layer is called the inner shell and is usually arranged on the inside of a building envelope when installed.

1. (I) eine erste Betonschicht,
2. (II) eine zweite Betonschicht und
3. (III) eine Dämmschicht, welche zwischen der ersten Betonschicht und der zweiten Betonschicht angeordnet ist,

besitzt,
wobei die Dämmschicht mineralisch basiert, insbesondere zementbasiert ist.According to a preferred embodiment of the present invention, it is provided that the precast concrete part has a multilayer structure

1. (I) a first layer of concrete,
2. (II) a second layer of concrete and
3. (III) an insulation layer which is arranged between the first concrete layer and the second concrete layer,

owns,
wherein the insulation layer is mineral-based, in particular cement-based.

According to this embodiment, it can be provided that the first concrete layer and the second concrete layer in particular at least regionally are arranged in parallel. With this special preferred embodiment of the present invention, which represent double-layer elements, in particular double-wall elements, in particular core-insulated wall and ceiling elements can be produced.

Likewise, it is usually provided that the insulation layer is arranged indirectly and / or directly on the first concrete layer and / or the second concrete layer.

In this context, it is preferred if the insulation layer is arranged directly on the first concrete layer. In the case of wall elements, the first concrete layer then preferably forms the outer shell and the second concrete layer forms the inner shell.

Likewise, it can be provided within the scope of the present invention that the insulation layer is arranged indirectly and / or directly, preferably directly, on the second concrete layer. This results in a massive double-shell, core-insulated wall or ceiling element, which is installed on site on the construction site and only needs to be joined with other elements.

According to a preferred embodiment of the present invention, however, it is provided that the insulation layer and the second concrete layer are spaced apart.

Preferably, within the scope of the present invention, a gap is provided between the insulation layer and the second concrete layer, so that a gap or cavity is created between the insulation layer and the second concrete layer, which is filled with concrete on site at the construction site, the so-called grouting - Or in-situ concrete, is filled so that joint-free concrete cores can be obtained for walls and ceilings, for example. The cavity or gap between the first concrete layer and the insulating layer preferably also contains reinforcement which, in particular, gives the casting or in-situ concrete the necessary strength and flexibility.

If the insulation layer and the second concrete layer are spaced apart, it has proven useful if the insulation layer and the second concrete layer are spaced 6 to 30 cm, in particular 7 to 20 cm, preferably 8 to 15 cm, preferably 9 to 12 cm .

In the context of the present invention it is usually provided that the precast concrete part has reinforcement. In general, the individual concrete layers can have reinforcements in order to increase the strength of the respective layers. According to preferred embodiments of the present invention, however, it is provided that the reinforcements penetrate several layers of the precast concrete part and connect them, whereby the overall stability of the precast concrete part is again significantly increased.

In the context of the present invention, it is advantageously provided that the precast concrete part is reinforced, in particular a first reinforcement made of a material with low thermal conductivity, in particular with a thermal conductivity of less than 5 W / (mK), preferably less than 2 W / (mK) , preferably less than 1 W / (mK).

By using reinforcements with low thermal conductivity, for example, a first concrete layer, which forms an outer shell of the precast concrete part, and an insulating layer can be connected without creating thermal bridges in the precast concrete part. When using steel reinforcements that extend from an outer shell into the insulation layer or through the insulation layer, considerable thermal bridges are created and the thermal insulation properties of the precast concrete part are significantly reduced overall.

In the context of the present invention, particularly good results are obtained when the material of the reinforcement, in particular the material of the first reinforcement, is selected from a material with low thermal conductivity from plastics, in particular from fiber-reinforced plastics, preferably from glass fiber and / or carbon fiber reinforced plastics.

The use of fiber-reinforced plastics makes it possible to provide reinforcements which, on the one hand, have only a low thermal conductivity, but on the other hand are mechanically strong enough to give the precast concrete part the necessary stability. Such reinforcements made of materials with low conductivity, in particular made of plastics, are only used to a very limited extent in order to give the precast concrete part the necessary stability, in particular to ensure that a precast concrete part with an outer shell and an insulating layer attached to it and an inner shell which is spaced from the insulation layer, as a precast concrete part can be processed. This reinforcement then connects the outer shell, ie the first concrete layer, with the inner shell, ie the second concrete layer, and penetrates the insulation layer, the cavity or gap between the insulation layer and the inner shell also being bridged. In addition to these reinforcements made of materials with low thermal conductivity, it can be provided and is advantageously provided that the concrete layers or at least one of the concrete layers has a steel reinforcement which, however, does not penetrate the insulation layer.

According to a preferred embodiment, it is provided that the reinforcement, in particular the first reinforcement, connects the first concrete layer and the second concrete layer. According to this embodiment, it is advantageously provided that the reinforcement, in particular the first reinforcement, penetrates the insulating layer.

In the context of the present invention, it is likewise advantageously provided that the precast concrete part has reinforcement, in particular a second reinforcement, made of a metal, in particular a ferrous metal, preferably steel. By using steel reinforcement, the precast concrete parts can be given improved mechanical properties. In particular, a significantly slimmer structure of the precast concrete part is possible.

In this context, it is preferred if the reinforcement, in particular the second reinforcement, is arranged in the second concrete layer and, if necessary, extends into the distance between the second concrete layer and the insulation layer. As stated above, when using metal reinforcements it is advantageous that they do not protrude into the insulation layer, in particular that they do not penetrate the insulation layer, as otherwise thermal bridges would arise or, with a large number of penetrations, the insulation properties of the precast concrete element are significantly reduced overall. At least one metal reinforcement is preferably anchored in the second concrete layer and protrudes into a gap or cavity between the second concrete layer and the insulation layer. If this gap or cavity is then filled with grouting or in-situ concrete on the construction site, it is possible to obtain a seamless reinforced concrete core of a building wall or ceiling.

According to a preferred embodiment of the present invention, it is therefore provided that the reinforcement, in particular the second reinforcement, in the second concrete layer and the cavity between the second concrete layer and the insulation layer is arranged.

As far as the combustibility of the precast concrete part is concerned, the precast concrete part usually has the combustibility A1 or A2 according to DIN 4102. The precast concrete part according to the invention is therefore purely mineral-based or almost exclusively mineral-based, so that costly fire protection measures can be omitted.

As far as the thickness of the insulation layer is concerned, it can vary within wide ranges depending on the respective requirements. Usually, however, the insulation layer has a layer thickness of 2 to 30 cm, in particular 3 to 25 cm, preferably 5 to 20 cm, preferably 8 to 15 cm. With the aforementioned insulation thicknesses, excellent thermal insulation up to a passive house standard can be achieved.

In the context of the present invention it can also be provided that the first concrete layer has a layer thickness of 1.5 to 15 cm, in particular 2 to 12 cm, preferably 3 to 10 cm, preferably 4 to 8 cm. The first concrete layer is usually used as the outer shell of the precast concrete part and is made from exposed concrete, for example.

Likewise, within the scope of the present invention it is usually provided that the second concrete layer has a layer thickness of 1.5 to 15 cm, in particular 2 to 12 cm, preferably 3 to 10 cm, preferably 4 to 8 cm.

According to a preferred embodiment of the present invention, it is provided that the surface of the insulating layer, in particular the surface of the insulating layer in edge areas, has been subjected to a surface treatment, in particular a treatment to strengthen the surface.

In order to protect the surface, in particular the edge areas, of the insulation layer from mechanical damage and to make it more resistant, it is possible for the surface of the insulation compound, in particular in edge areas, to be treated with a surface treatment agent. The surface treatment agent is preferably an aqueous dispersion which has water glass and fibers, in particular mineral fibers.

According to a preferred embodiment of the present invention, the surface modifier has 5 to 50% by weight, in particular 8 to 40% by weight, in particular 10 to 35% by weight of water glass, in particular sodium and / or potassium water glass, based on the surface treatment agent, on.

The surface treatment agent advantageously further comprises 0.5 to 10% by weight, in particular 0.5 to 8% by weight, preferably 1 to 5% by weight, of mineral fibers, in particular wollastonite fibers and / or calcium silicate fibers, based on the surface treatment agent .

Likewise, it can be provided that the surface treatment agent has 0.01 to 5% by weight, in particular 0.1 to 3% by weight, preferably 0.2 to 1% by weight, of a water repellent, based on the surface treatment agent. The hydrophobing agent is usually selected from silanes, siloxanes, siliconates and mixtures thereof.

As stated above, the surface treatment agent is preferably used in the form of an aqueous dispersion, d. H. the surface treatment agent contains water as a dispersant.

The surface treatment agent can be applied to the insulation layer, in particular the edges of the insulation layer, in any suitable manner. Usually, however, the surface treatment agent is applied to the surface of the insulating layer by spraying, brushing, rolling or knife coating, preferably by spraying or spraying. After treatment with the surface treatment agent, the surface of the insulating layer is preferably stored at room temperature or in a climatic chamber in the temperature range from 40 to 60 ° C., as a result of which the surface treatment agent is hardened.

In the context of the present invention it is preferably provided that the precast concrete part is a wall element and / or a ceiling element. Preferably it is a double layer element, i. H. around a core-insulated precast concrete part with an inner and an outer shell made of concrete, which can be used for the production of ceilings and walls in buildings.

Fig. 1

eine Schnittdarstellung eines erfindungsgemäßen Betonfertigteils,

Fig. 2

einen Schnitt durch ein erfindungsgemäßes Fertigteil, bei welchem Dämmschicht und zweite Betonschicht beanstandet sind,

Fig. 3

eine perspektivische Darstellung des in Fig. 2 dargestellten erfindungsgemäßen Betonfertigteils und

Fig. 4

ein erfindungsgemäßes zweischichtiges Betonfertigteil.

It shows the figure representations according to

Fig. 1

a sectional view of a precast concrete part according to the invention,

Fig. 2

a section through a prefabricated part according to the invention, in which the insulation layer and the second concrete layer are defective,

Fig. 3

a perspective view of the in Fig. 2 illustrated precast concrete part according to the invention and

Fig. 4

a two-layer precast concrete part according to the invention.

Another object of the present invention - according to a second aspect of the present invention - is the use of a precast concrete part as described above for creating structures, in particular houses.

For further details on the use of a precast concrete part according to the invention, reference can be made to the above statements on the precast concrete part according to the invention, which apply accordingly with regard to the use of the precast concrete part.

1. (A) ein zementbasiertes Bindemittel in Mengen von 5 bis 50 Gew.-%, bezogen auf die Baustofftrockenmischung,
2. (B) ein Aerogel in Mengen von 3 bis 50 Gew.-%, bezogen auf die Baustofftrockenmischung, und
3. (C) mindestens einen Leichtzuschlag in Mengen von 5 bis 60 Gew.-%, bezogen auf die Baustofftrockenmischung,

aufweist.Yet another subject matter of the present invention - according to a third aspect of the present invention - is a dry building material mix for producing an insulating compound for producing an insulating layer, the dry building material mix

1. (A) a cement-based binder in amounts of 5 to 50% by weight, based on the dry building material mix,
2. (B) an airgel in amounts of 3 to 50% by weight, based on the dry building material mix, and
3. (C) at least one lightweight aggregate in quantities of 5 to 60% by weight, based on the dry building material mix,

having.

The dry building material mix according to the invention is outstandingly suitable for producing the above-described insulating layer of a precast concrete part according to the invention.

With the dry building material mix according to the invention, cement-based insulating compounds can be produced in particular, which form a particularly intimate and permanent bond with concrete. In the case of the dry building material mix according to the invention and the insulating material obtainable therefrom or the this mortar that can be obtained is merely a preferred dry building material mix or a preferred insulating material which can be used in the context of the present invention for the production of the precast concrete part according to the invention; other cement-based insulating compounds can also be used with great success, the best results so far being achieved with insulating compounds based on the dry building material mix according to the invention. The dry building material mixture according to the invention and the insulating compound according to the invention obtainable therein are particularly notable for the fact that they contain both an airgel and a lightweight aggregate in large quantities, so that an insulating compound with excellent thermal insulation properties is obtained.

According to a preferred embodiment of the present invention, the cement-based binding agent is Portland cement, in particular white cement, preferably rapid cement. Rapid cements are cements with a very short pot life of a few minutes, usually approx. 2 to 3 minutes, the liquid mass solidifying within an hour, often after 5 to 7 minutes. Rapid cement is cements, in particular Portland cement, preferably white cement, to which accelerators are added. Suitable accelerators are, for example, aluminum salts, in particular aluminum sulfate, calcium sulfoaluminate or basic aluminum salts, and also accelerators based on calcium nitrate. A precast concrete part can be produced in a very short time, in particular through the use of rapid cement.

According to a preferred embodiment of the present invention, the dry building material mix contains the cement-based binder in amounts of 10 to 45% by weight, preferably 15 to 40% by weight, preferably 20 to 30% by weight, based on the dry building material mix.

As far as the airgel used in the context of the dry building material mix according to the invention is concerned, it has proven useful if the airgel is an inorganic, in particular a predominantly inorganic, airgel. Particularly good results are obtained when the airgel is a silica airgel and / or a silica hybrid airgel. Particularly through the use of silica aerogels or silica hybrid aerogels, particularly good thermal insulation properties can be achieved, with further properties of the properties obtained at the same time Insulating material, such as the flammability and mechanical strength, are not negatively affected.

Particularly good results are obtained in the context of the present invention when the dry building material mixture contains the airgel in amounts of 5 to 40% by weight, preferably 10 to 35% by weight, preferably 15 to 30% by weight, based on the dry building material mixture, contains.

The aerogels used usually have a particle size of 0.01 to 10 mm, in particular 0.05 to 8 mm, preferably 0.1 to 7 mm, preferably 0.2 to 6 mm, particularly preferably 0.5 to 5 mm, very particularly preferably 0.5 to 4 mm, extremely preferably 0.5 to 2 mm.

Aerogels with the aforementioned particle sizes can be incorporated excellently into cement-based insulating compounds and, with regard to their particle size, complement each other with the lightweight aggregates in such a way that the sensitive airgel particles fill the spaces in a spherical packing of the particles of the lightweight aggregate and can be incorporated into the insulating compound largely without destruction, so that insulation compounds with excellent thermal insulation properties are obtained.

Likewise, the aerogels generally have a bulk density in the range from 0.05 to 20 g / cm ³ , in particular 0.08 to 0.27 g / cm ³ , preferably 0.12 to 0.25 g / cm ³ , preferably 0 , 13 to 0.22 g / cm ³ , particularly preferably 0.14 to 0.20 g / cm ³ , very particularly preferably 0.15 to 0.16 g / cm ³ .

Likewise, it can be provided that the airgel has absolute pore diameters in the range from 2 to 400 nm, in particular 5 to 300 nm, preferably 8 to 200 nm, preferably 10 to 130 nm, particularly preferably 10 to 70 nm . Aerogels with pore diameters in the aforementioned areas have excellent thermal insulation properties.

As already stated above, the dry building material mix according to the invention has a light aggregate. Particularly good results are obtained in this context if the lightweight aggregate is selected from the group of volcanic rock, perlite, in particular expanded perlite, vermiculite, in particular expanded vermiculite, pumice, foam and expanded glass, expanded clay, expanded slate, tuff, expanded mica, lava gravel, Lava sand, and mixtures thereof.

According to a preferred embodiment of the present invention, the lightweight aggregate is selected from the group of perlite, in particular expanded perlite, vermiculite, in particular expanded vermiculite, and mixtures thereof. It is particularly preferred in this context if the lightweight aggregate is expanded perlite.

As far as the particle or grain size of the lightweight aggregate is concerned, this can of course vary within wide ranges. However, it has proven useful if the lightweight aggregate has grain sizes of at most 4 mm, in particular at most 3 mm. With particle or grain sizes in the aforementioned ranges, particularly suitable mixtures with the airgel can be obtained, in which the airgel particles are not destroyed even when using mixing machines for the production of insulating compounds from the dry building material mix.

According to a preferred embodiment of the present invention, the dry building material mix contains the lightweight aggregate in amounts of 10 to 50% by weight, preferably 15 to 40% by weight, preferably 20 to 30% by weight, based on the dry building material mix.

In the context of the present invention, particularly good results are also obtained when the dry building material mix contains the airgel and the lightweight aggregate in a weight-based ratio of lightweight aggregate to airgel of 15: 1 to 1:10, in particular 10: 1 to 1: 8, preferably 5: 1 up to 1: 5, preferably 2: 1 to 1: 2, particularly preferably 2: 1 to 1: 1.

In the context of the present invention, it is further preferred if the dry building material mixture has a lime-based binder, in particular lime, preferably hydraulic lime. By using lime-based binders, the setting of the binder is accelerated again. In addition, lime has a very high pH value, which, for example, counteracts the formation of mold.

If the dry building material mixture contains a lime-based binder, it has proven useful if the dry building material mixture prefers the lime-based binder in amounts of 3 to 40% by weight, in particular 5 to 30% by weight, preferably 8 to 28% by weight 10 to 20% by weight, based on the dry building material mixture.

Furthermore, it can be provided within the scope of the present invention that the dry building material mix has fibers, in particular inorganic fibers, preferably inorganic mineral fibers. The use of fibers can significantly increase the strength and mechanical resistance of the resulting insulation materials. In particular, it is possible to reduce the proportion of binders so that the thermal insulation properties of the insulation layers obtained are improved.

As already stated above, it is preferred in the context of the present invention if the fibers are selected from calcium silicate fibers, glass fibers, wollastonite fibers, carbon fibers, carbon nanotubes and mixtures thereof. However, particularly good results are obtained when the fibers are calcium silicate fibers.

With regard to the amount in which the dry building material mixture contains the fibers, it has proven useful if the dry building material mixture contains the fibers in amounts of 0.1 to 10% by weight, in particular 0.5 to 5% by weight, preferably 1 to 4% by weight, preferably 2 to 4% by weight, based on the dry building material mixture. Even with small proportions of fibers, a significant increase in the mechanical properties of the resulting mortar or insulation mass can be achieved and thus the proportion of the binder can be reduced.

According to a preferred embodiment of the present invention it is provided that the dry building material mixture has at least one pore former. The presence of a pore-forming agent improves, in particular, the frost resistance of the insulation layer and the flow properties of the resulting mortar or insulation mass, so that only a little water is required to make the insulation mass. In principle, all known pore formers, in particular air entrainers, can be used in the context of the present invention. The pore former is usually selected from lignosulfonates, carboxyl compounds, protein acids and resins, in particular tall resins and balsam resins.

If the dry building material mixture contains a pore former, the dry building material mixture usually contains the pore former in amounts of 0.1 to 5% by weight, in particular 0.5 to 5% by weight, preferably 1 to 4% by weight, preferably 2 to 4% by weight, based on the dry building material mix.

In addition, it can be provided within the scope of the present invention that the dry building material mixture also has at least one additive. If the dry building material mix has an additive, the additive is usually selected from the group of thickeners, retarders, accelerators, stabilizers (stabilizers), rheology control agents, additives to adjust the water retention capacity (water retention agents), dispersants, sealants and mixtures thereof. In the event that the dry building material mix has an additive, the dry building material mix usually has the additive in amounts of 0.01 to 10% by weight, in particular 0.1 to 5% by weight, preferably 0.3 to 3% by weight. -%, preferably 0.5 to 1% by weight, based on the dry building material mixture.

For further details on the dry building material mix according to the invention, reference can be made to the above statements on the other aspects of the invention, which apply accordingly in relation to the dry building material mix according to the invention.

Another object of the present invention - according to a fourth aspect of the present invention - is the use of the aforementioned dry building material mix for producing an insulating compound, in particular a mortar.

Usually, a mortar or an insulating compound is obtained from the dry building material mix according to the invention by mixing with water, d. H. In the context of the present invention, the dry building material mixture is mixed with water and mixed to produce the insulating material.

If the dry building material mix is made up with water to produce an insulating compound, it has proven useful if the dry building material mix is mixed with water in a ratio of dry building material to water of 1: 0.5 to 1: 2, in particular 1: 0.6 to 1: 1.8, preferably 1: 0.7 to 1: 1.6, preferably 1: 0.8 to 1: 1.4, is made up.

It can be turned on by hand or by machine. The dry building material mix is preferably mixed with the water in a compulsory mixer. In this context, mixing times between 1 and 10 minutes, preferably 1 and 5 minutes, are preferably required.

Particularly good results are obtained when the water has a temperature between 20 and 70.degree. C., in particular 25 to 65.degree. C., preferably 30 to 60.degree. With water in the aforementioned temperature range, it is possible to obtain a mortar which has temperatures of 20 to 60 ° C., in particular 20 to 50 ° C., and which hardens quickly due to the increased temperature.

For further details on the use according to the invention of a dry building material mix, reference can be made to the above statements on the further aspects of the invention, which apply accordingly in relation to the use according to the invention.

Yet another subject matter of the present invention - according to a fifth aspect of the present invention - is an insulating compound, in particular a mortar, produced from the dry building material mix described above by mixing with water.

For further details on the insulating compound according to the invention, reference can be made to the above statements on the further aspects of the invention, which apply accordingly in relation to the insulating compound according to the invention.

1. (a) in einem ersten Verfahrensschritt eine hohle Form, insbesondere eine Schalung, vorgelegt wird,
2. (b) nachfolgend in einem zweiten Verfahrensschritt flüssiger Beton zur Ausbildung einer ersten Betonschicht in die hohle Form gefüllt wird, insbesondere bis zu einer vorgegebenen Füllhöhe,
3. (c) anschließend in einem auf den zweiten Verfahrensschritt (b) folgenden dritten Verfahrensschritt eine mineralisch basierte, insbesondere zementbasierte, Dämmmasse zur Ausbildung einer Dämmschicht in die hohle Form eingefüllt wird, so dass ein Rohdämmelement mit einer Betonschicht und einer Dämmschicht gebildet wird, und

nachfolgend das Rohdämmelement ausgehärtet, insbesondere teilweise ausgehärtet wird, so dass ein Dämmelement erhalten wird.Finally, the present invention further provides - according to a sixth aspect of the present invention - a method for producing a precast concrete part, in particular as described above, wherein

1. (a) in a first process step a hollow form, in particular a formwork, is presented,
2. (b) subsequently, in a second process step, liquid concrete is poured into the hollow form to form a first concrete layer, in particular up to a specified fill level,
3. (c) then, in a third process step following the second process step (b), a mineral-based, in particular cement-based, insulating compound is poured into the hollow form to form an insulating layer, so that a raw insulating element is formed with a concrete layer and an insulating layer, and

subsequently the raw insulating element is cured, in particular partially cured, so that an insulating element is obtained.

In the context of the present connection, an insulating element is to be understood as an at least two-layer precast concrete part made of a concrete layer and an insulating layer, in which the concrete layer and the insulating layer are at least partially formed. The insulating element can either be further processed, for example to form double-layer elements, which have at least two concrete layers, or, if necessary, can be installed after a post-curing process.

With regard to the temperatures at which the raw insulation element is cured, in particular partially cured, it has proven useful if the raw insulation element is at temperatures in the range from 20 to 80 ° C, in particular 30 to 70 ° C, preferably 40 to 60 ° C , is cured. The curing takes place preferably in a climatic chamber. In this context, it is usually provided that the raw insulation element is only partially cured, ie. H. that the raw insulation element is dimensionally stable, but not yet fully cured.

As regards the period of time over which the raw insulation element is cured, the raw insulation element is usually cured over a period of 4 to 20 hours, in particular 5 to 15 hours, preferably 8 to 12 hours. During the aforementioned curing times, the raw insulation element is cured to such an extent that it is dimensionally stable and can be further processed, although the production capacities are not unnecessarily burdened by long storage times.

In the context of the present invention it can also be provided that the raw insulation element is provided with reinforcement, in particular a first reinforcement. The reinforcement can either be present alone in the first concrete layer or connect the concrete layer and the insulation layer or be anchored in the concrete layer and, if necessary, extend beyond the insulation layer.

In this context, it can be provided that the reinforcement is presented in the hollow form in the first process step (a) or that the reinforcement is introduced into the raw insulation element following the third process step (c), in particular by pressing it into the still liquid concrete layer and / or insulation layer. In the context of the present invention, it is preferred if the reinforcement after the third process step (c) in the Rohdämmelement is introduced, in particular before curing of the Rohdämmelementes.

This applies in particular when reinforcement is used which extends both within the concrete layer and within the insulation layer and, if necessary, protrudes beyond the insulation layer.

Particularly good results are obtained when the reinforcement consists of a material with low thermal conductivity, in particular a thermal conductivity of less than 5 W / (mK), preferably less than 2 W / (mK), preferably less than 1 W / (mK) . In particular, it is preferred in this context if the material is the reinforcement selected from plastics, in particular from fiber-reinforced plastics, preferably from glass fiber and / or carbon fiber reinforced plastics.

According to a preferred embodiment of the present invention it is provided that the reinforcement extends from the concrete layer into the insulation layer of the raw insulation element. In this context, it is particularly preferred if the reinforcement extends from the concrete layer beyond the insulation layer of the raw insulation material and thus connects the concrete layer and the insulation layer with a further concrete layer, for example. In the context of the present invention, it is also preferred if, after the liquid concrete has been poured into the hollow mold in the second process step (b), compaction is carried out, in particular by shaking. It is likewise preferred if, after the insulating compound has been filled in, compaction, in particular by shaking, is carried out. If compaction takes place after the insulation material has been poured in, it can either be dispensed with after the concrete has been poured in or it is compacted after the concrete has been poured in as well as after the insulation material has been poured in. In the context of the present invention, it is preferred if compression is carried out both after the concrete has been poured in and after the insulating compound has been poured in.

In the context of the present invention it is usually provided that the insulating element is removed from the hollow form, in particular the formwork, in particular after it has hardened. After removing the formwork, the insulating element can either be used immediately or, for example, further processed, in particular into a double-layer element.

In the context of the present invention, it can also be provided that after the insulation element has been removed from the hollow form, in particular the formwork, the insulation element is subjected to a process step for hardening the surface of the insulation layer, in particular the surface of the edges of the insulation layer. The method for treating the surface of the insulating layer is preferably carried out using a surface treatment agent as set out above.

Within the scope of the present invention, it can furthermore be provided that, in particular following the method steps described above, a further hollow form, in particular formwork, is presented and filled with liquid concrete to form a second concrete layer, in particular up to a specified fill level and then the insulating element is connected to the side of the insulating layer with the second concrete layer cohesively or at a distance, preferably at a distance, so that a raw double-layer element, in particular a raw double-wall element, is obtained.

In the context of the present invention, the procedure is preferably such that after completion of the insulating element, the insulating element is removed from the formwork and then a second formwork is presented and filled with concrete. The insulating element is then connected to the side of the insulating layer with the second concrete layer, either by placing the insulating layer directly on the second concrete layer, which leads to a material connection, or by immersing and / or pressing in a reinforcement that is present in the insulating element and protrudes beyond the insulation layer, into the second concrete layer, so that the insulation layer can be spaced from the second concrete layer and a precast concrete part is still obtained.

In this context, it can furthermore be provided that after the second concrete layer has been filled into the hollow form, the second concrete layer is compacted, in particular by shaking.

In the context of the present invention it is usually provided that the raw double-layer element is cured, in particular partially cured. Particularly good results are obtained in this context if the raw double-layer element is cured at temperatures in the range from 20 to 80 ° C., in particular 30 to 70 ° C., preferably 40 to 80 ° C., so that a double-layer element, in particular a double-wall element, is obtained becomes.

It has also proven useful if the raw double-layer element is cured for a period of 4 to 20 hours, in particular 5 to 15 hours, preferably 8 to 12 hours.

In the context of the present invention, it can be provided according to a preferred embodiment that the insulating element is provided with a second reinforcement before it is connected to the second concrete layer or that the further hollow shape is provided with a second reinforcement. The second reinforcement can be attached to the first reinforcement, for example. Alternatively, it can also be provided that the second reinforcement is anchored to the insulation layer, but the insulation layer is not penetrated. The second reinforcement preferably does not penetrate the insulation layer in any embodiment of the present invention. It is particularly preferred if the second reinforcement does not penetrate into the insulation layer.

Usually, within the scope of the present invention, it is provided that the second reinforcement consists of a metal, in particular an iron-containing metal, preferably steel.

According to a preferred configuration of this embodiment, it is provided that the second reinforcement extends in the second concrete layer and / or that the second reinforcement extends beyond the second concrete layer, in particular into the cavity or gap between the second concrete layer and the insulation layer.

In the context of the present invention it is usually provided that the double-layer element is then removed from the second hollow mold.

After the double-layer element has been removed from the second hollow mold, the double-wall element is usually post-cured, in particular over a period of 2 to 4 weeks. Post-curing is usually done by storage at ambient conditions.

1. (a) in einem ersten Verfahrensschritt eine hohle Form, insbesondere eine Schalung, vorgelegt wird,
2. (b) nachfolgend in einem zweiten Verfahrensschritt flüssiger Beton zur Ausbildung einer ersten Betonschicht in die hohle Form gefüllt wird, insbesondere bis zu einer vorgegebenen Füllhöhe, und gegebenenfalls die Betonschicht verdichtet wird,
3. (c) anschließend in einem auf den zweiten Verfahrensschritt (b) folgenden dritten Verfahrensschritt eine mineralisch basierte, insbesondere zementbasierte, Dämmmasse zur Ausbildung einer Dämmschicht in die hohle Form eingefüllt wird, so dass ein Rohdämmelement mit einer Betonschicht und einer Dämmschicht gebildet wird, und gegebenenfalls die Dämmschicht bzw. die erste Betonschicht und die Dämmschicht verdichtet wird,
4. (d) in einem nachfolgenden vierten Verfahrensschritt das Rohdämmelement mit einer ersten Bewehrung versehen wird,
5. (e) nachfolgend in einem fünften Verfahrensschritt das Rohdämmelement ausgehärtet, insbesondere teilweise ausgehärtet, wird, so dass ein Dämmelement erhalten wird,
6. (f) gegebenenfalls in einem nachfolgenden sechsten Verfahrensschritt das Dämmelement aus der hohlen Form entfernt wird,
7. (g) gegebenenfalls in einem siebten Verfahrensschritt die Oberfläche der Dämmschicht, insbesondere die Oberflächen der Kanten der Dämmschicht, einer Oberflächenbehandlung unterzogen werden,
8. (h) nachfolgend, insbesondere in einem achten Verfahrensschritt, das Dämmelement mit einer zweiten Bewehrung versehen wird,
9. (i) wiederum nachfolgend, insbesondere in einem neunten Verfahrensschritt, eine zweite hohle Form, insbesondere Schalung, vorgelegt wird,
10. (j) nachfolgend, insbesondere in einem zehnten Verfahrensschritt, die zweite hohle Form bis zu einer vorgegebenen Füllhöhe befüllt wird, so dass eine zweite Betonschicht gebildet wird, und gegebenenfalls die zweite Betonschicht verdichtet wird,
11. (k) nachfolgend, insbesondere in einem elften Verfahrensschritt, das Dämmelement mit der Seite der Dämmschicht mit der zweiten Betonschicht verbunden wird, insbesondere über die erste Bewehrung, so dass ein Rohdoppelschichtelement erhalten wird,
12. (l) nachfolgend, insbesondere in einem zwölften Verfahrensschritt, das Rohdoppelwandelement ausgehärtet, insbesondere teilweise ausgehärtet wird, so dass ein Doppelschichtelement erhalten wird,
13. (m) nachfolgend, insbesondere in einem dreizehnten Verfahrensschritt, das Doppelschichtelement aus der zweiten hohlen Form entfernt wird und
14. (n) nachfolgend, insbesondere in einem vierzehnten Verfahrensschritt, das Doppeschichtelement nachgehärtet wird.

According to a preferred embodiment of the present invention, the present invention relates to a previously described method for producing a precast concrete part as described above, wherein

1. (a) in a first process step a hollow form, in particular a formwork, is presented,
2. (b) subsequently, in a second process step, liquid concrete is poured into the hollow form to form a first concrete layer, in particular up to a specified fill level, and the concrete layer is optionally compacted,
3. (c) then, in a third process step following the second process step (b), a mineral-based, in particular cement-based, insulating compound for forming an insulating layer is poured into the hollow form, so that a raw insulating element is formed with a concrete layer and an insulating layer, and optionally the insulation layer or the first concrete layer and the insulation layer are compacted,
4. (d) in a subsequent fourth process step, the raw insulation element is provided with a first reinforcement,
5. (e) subsequently, in a fifth process step, the raw insulation element is cured, in particular partially cured, so that an insulation element is obtained,
6. (f) if necessary, in a subsequent sixth process step, the insulating element is removed from the hollow mold,
7. (g) if necessary, in a seventh process step, the surface of the insulating layer, in particular the surfaces of the edges of the insulating layer, are subjected to a surface treatment,
8. (h) subsequently, in particular in an eighth process step, the insulating element is provided with a second reinforcement,
9. (i) again subsequently, in particular in a ninth process step, a second hollow form, in particular formwork, is presented,
10. (j) subsequently, in particular in a tenth process step, the second hollow mold is filled up to a predetermined filling level, so that a second concrete layer is formed and, if necessary, the second concrete layer is compacted,
11. (k) subsequently, in particular in an eleventh process step, the insulating element is connected to the side of the insulating layer with the second concrete layer, in particular via the first reinforcement, so that a raw double-layer element is obtained,
12. (l) subsequently, in particular in a twelfth process step, the raw double-wall element is cured, in particular partially cured, so that a double-layer element is obtained,
13. (m) subsequently, in particular in a thirteenth method step, the double-layer element is removed from the second hollow mold and
14. (n) subsequently, in particular in a fourteenth process step, the double-layer element is post-cured.

For further details on the method according to the invention, reference can be made to the above statements on the other aspects of the invention, which apply accordingly in relation to the method according to the invention.

The subject matter of the present invention is explained and specified in more detail below by the description of the figures and the exemplary embodiments using preferred embodiments, without, however, restricting the subject matter of the present invention to these specific and preferred embodiments.

It shows Fig. 1 In a cross-sectional view, a layer structure of a precast concrete part 1 according to the invention, which is formed from two parallel concrete layers 2 and 3, namely a first concrete layer 2 in the form of an outer shell and a second concrete layer 3 in the form of an inner shell, and an insulation layer 4 lying between the concrete layers 2 and 3 becomes.

In the in Fig. 1 The selected embodiment, both the first concrete layer 2 and the second concrete layer 3 are each materially and directly connected to the insulation layer 4. According to this embodiment, it can be provided that the first concrete layer 2 has reinforcement not shown in the figure, in particular steel reinforcement, and / or that the second concrete layer 3 has reinforcement, in particular steel reinforcement. These reinforcements, in particular steel reinforcements, preferably do not penetrate the insulating layer 4. Equally, it can be provided that a reinforcement connects the first concrete layer 2 and the second concrete layer 3 to one another, ie penetrates the insulation layer. In this case, the reinforcement usually consists of a material with little thermal conductivity, preferably fiber-reinforced plastics.

It shows Fig. 2 a cross section of a further and preferred embodiment of a precast concrete part 1 according to the invention in the form of a double-layer element, in particular a double-wall element, which has a first concrete layer 2 as an outer shell and a second concrete layer 3 as an inner shell. An insulation layer 4 and a cavity 5 are arranged between the first concrete layer 2 and the second concrete layer 3. When the precast concrete part 1 is installed, the cavity 5 is filled with casting or in-situ concrete, so that a continuous, seamless concrete layer is obtained over several precast concrete parts 1.

The precast concrete part 1 also has a first reinforcement 6, which preferably consists of a material with little heat conductivity, in particular a fiber-reinforced plastic, in particular a carbon fiber-reinforced plastic. The reinforcement 6 connects the first concrete layer 2 with the second concrete layer 3 and completely penetrates the insulation layer 4. The reinforcement 6 gives the precast concrete part 1 on the one hand its strength and allows the construction of the cavity 5, d. H. a double-layer element, in particular a double-wall element, which is filled with in-situ concrete or grouting concrete on site at the construction site.

Furthermore, the precast concrete part 1 has a second reinforcement 7 made of steel, which is fastened to the first reinforcement 6 and, in addition, is fastened, in particular anchored, in the second concrete layer 3.

Fig. 3 shows a perspective view of the in Fig. 2 illustrated precast concrete part 1.

1. 1. Betonfertigteil (1), aufweisend mindestens eine Betonschicht (2) und eine Dämmschicht (4), wobei die Dämmschicht (4) an der Betonschicht angeordnet ist,
   dadurch gekennzeichnet,
   dass die Dämmschicht (4) mineralisch basiert, insbesondere zementbasiert, ist.
2. 2. Betonfertigteil nach Aspekt 1, dadurch gekennzeichnet, dass die Dämmschicht (4) mittelbar und/oder unmittelbar, vorzugsweise unmittelbar, an der Betonschicht (2) angeordnet ist, insbesondere auf diese aufgebracht ist.
3. 3. Betonfertigteil (1) nach Aspekt 2, dadurch gekennzeichnet, dass die Dämmschicht (4) ohne Verwendung von Klebstoffen und/oder Mörteln an der Betonschicht (2) angeordnet ist.
4. 4. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die Dämmschicht (4) mindestens eine Fläche der Betonschicht (2) insbesondere zumindest bereichsweise, vorzugsweise zum überwiegenden Teil, bevorzugt nahezu vollflächig, bedeckt.
5. 5. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die Dämmschicht (4) zu mindestens 90 Gew.-%, insbesondere 95 Gew.-%, vorzugsweise 97 Gew.-%, bevorzugt 98 Gew.-%, bezogen auf die Dämmschicht (4), aus anorganischen Materialien besteht.
6. 6. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die Dämmschicht (4) zu 90 bis 100 Gew.-%, insbesondere 95 bis 100 Gew.-%, vorzugsweise 97 bis 100 Gew.-%, bevorzugt 98 bis 100 Gew.-%, bezogen auf die Dämmschicht (4), aus anorganischen Materialien besteht.
7. 7. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die Dämmschicht (4) anorganische Füllstoffe, insbesondere mineralische Füllstoffe, in Mengen von mindestens 20 Gew.-%, insbesondere 40 Gew.-%, vorzugsweise 50 Gew.-%, bevorzugt 60 Gew.-%, bezogen auf die Dämmschicht (4), aufweist.
8. 8. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die Dämmschicht (4) anorganische Füllstoffe, insbesondere mineralische Füllstoffe, in Mengen von 20 bis 80 Gew.-%, insbesondere 40 bis 75 Gew.-%, vorzugsweise 50 bis 70 Gew.-%, bevorzugt 60 bis 70 Gew.-%, bezogen auf die Dämmschicht (4), aufweist.
9. 9. Betonfertigteil (1) nach Aspekt 7 oder 8, dadurch gekennzeichnet, dass der anorganisch Füllstoffe ausgewählt aus der Gruppe von vulkanischem Gestein, Perlit, insbesondere geblähtem Perlit, Vermiculit, insbesondere geblähtem Vermiculit, Bims, Schaum- und Blähglas, Blähton, Blähschiefer, Tuff, Blähglimmer, Lavakies, Lavasand, Silica-Aerogelen, Silica-Hybridaerogelen und deren Mischungen, vorzugsweise ausgewählt ist aus der Gruppe von Perlit, insbesondere geblähtem Perlit, Vermiculit, insbesondere geblähtem Vermiculit, Aerogelen, insbesondere Silica-Aerogelen und/oder Silica-Hybridaerogelen, und deren Mischungen, bevorzugt deren Mischungen.
10. 10. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die Dämmschicht (4) einen Leichtzuschlag ausgewählt aus der Gruppe von vulkanischem Gestein, Perlit, insbesondere geblähtem Perlit, Vermiculit, insbesondere geblähtem Vermiculit, Bims, Schaum- und Blähglas, Blähton, Blähschiefer, Tuff, Blähglimmer, Lavakies, Lavasand und deren Mischungen, vorzugsweise ausgewählt aus der Guppe von Perlit, insbesondere geblähtem Perlit, Vermiculit, insbesondere geblähtem Vermiculit, und deren Mischungen, in Kombination mit einem anorganischen Füllstoff in Form eines Aerogels, insbesondere eines Silica-Aerogels und/oder eines Silica-Hybridaerogels, aufweist.
11. 11. Betonfertigteil (1) nach Aspekt 10, dadurch gekennzeichnet, dass die Dämmschicht (4) einen gewichtsbezogenes Verhältnis von Leichtzuschlag zu Aerogel im Bereich von 15 : 1 bis 1 : 10, insbesondere 10 : 1 bis 1 : 8, vorzugsweise 5 : 1 bis 1 : 5, bevorzugt 2 : 1 bis 1 : 2, besonders bevorzugt 2 : 1 bis 1 : 1, aufweist.
12. 12. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die Dämmschicht (4) Fasern, insbesondere anorganische Fasern, vorzugsweise mineralische, Fasern, enthält.
13. 13. Betonfertigteil (1) nach Aspket 12, dadurch gekennzeichnet, dass die Fasern ausgewählt sind aus Calciumsilikatfasern, Glasfasern, Wollastonitfasern, Kohlenstofffasern, Kohlenstoffnanoröhren und deren Mischungen, vorzugsweise Calciumsilikatfasern sind.
14. 14. Betonfertigteil (1) nach Aspekt 12 oder 13, dadurch gekennzeichnet, dass die Dämmschicht (4) die Fasern in Mengen von 0,1 bis 20 Gew.-%, insbesondere 0,2 bis 15 Gew.-%, insbesondere 0,5 bis 12 Gew.-%, bevorzugt 1 bis 10 Gew.-%, bezogen auf die Dämmschicht (4), aufweist.
15. 15. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die Dämmschicht (4) ein zementbasiertes Bindemittel aufweist.
16. 16. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die Dämmschicht (4) eine Wärmeleitfähigkeit im Bereich von 0,025 bis 0,050 W/(mK), insbesondere 0,030 bis 0,045 W/(mK), vorzugsweise 0,035 bis 0,042 W/(mK), aufweist.
17. 17. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die Dämmschicht (4) eine Wasserdampfdiffusionswiderstandszahl µ, bestimmt nach DIN EN ISO 12542, im Bereich von 2 bis 9, insbesondere 3 bis 7, vorzugsweise 4 bis 6, aufweist.
18. 18. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die Dämmschicht (4) eine Trockenrohdichte im Bereich von 125 bis 250 kg/m³, insbesondere 140 bis 225 kg/m³, vorzugsweise 150 bis 200 kg/m³, aufweist.
19. 19. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die Dämmschicht (4) die Brennbarkeit A1 oder A2 gemäß DIN 4102 aufweist.
20. 20. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass das Betonfertigteil (1) ein kerngedämmtes Betonfertigteil ist.
21. 21. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass das Betonfertigteil (1) einen mehrschichtigen Aufbau, aufweisend
    1. (I) einer erste Betonschicht (2),
    2. (II) eine zweite Betonschicht (3) und
    3. (III) eine Dämmschicht (4), welche zwischen der ersten Betonschicht (2) und der zweiten Betonschicht (3) angeordnet ist,
    besitzt,
    dadurch gekennzeichnet,
    dass die Dämmschicht (4) mineralisch basiert, insbesondere zementbasiert, ist.
22. 22. Betonfertigteil (1) nach Aspekt 20 oder 21, dadurch gekennzeichnet, dass die erste Betonschicht (2) und die zweite Betonschicht (3) insbesondere zumindest bereichsweise parallel angeordnet sind.
23. 23. Betonfertigteil (1) nach einem der Aspekte 20 bis 22, dadurch gekennzeichnet, dass die Dämmschicht (4) mittelbar und/oder unmittelbar an der ersten Betonschicht (2) und/oder der zweiten Betonschicht (3) angeordnet ist.
24. 24. Betonfertigteil (1) nach Aspekt 23, dadurch gekennzeichnet, dass Dämmschicht (4) unmittelbar an der ersten Betonschicht (2) angeordnet ist.
25. 25. Betonfertigteil (1) nach Aspket 23 oder 24, dadurch gekennzeichnet, dass Dämmschicht (4) mittelbar und/oder unmittelbar, vorzugsweise unmittelbar, an der zweiten Betonschicht (3) angeordnet ist.
26. 26. Betonfertigteil (1) nach einem der Aspekte 20 bis 24, dadurch gekennzeichnet, dass die Dämmschicht (4) und die zweite Betonschicht (3) beabstandet sind.
27. 27. Betonfertigteil (1) nach Aspekt 26, dadurch gekennzeichnet, dass die Dämmschicht (4) und die zweite Betonschicht (3) einen Abstand von 6 bis 30 cm, insbesondere 7 bis 20 cm, vorzugsweise 8 bis 15 cm, bevorzugt 9 bis 12 cm, aufweisen.
28. 28. Betonfertigteil (1) nach einem der Aspekte 20 bis 27, dadurch gekennzeichnet, dass das Betonfertigteil (1) mindestens eine Bewehrung (6,7) aufweist.
29. 29. Betonfertigteil (1) nach einem der Aspekte 20 bis 28, dadurch gekennzeichnet, dass das Betonfertigteil (1) eine Bewehrung (6), insbesondere eine erste Bewehrung, aus einem Material mit geringer Wärmeleitfähigkeit, insbesondere mit einer Wärmeleitfähigkeit von weniger als 5 W/(mK), vorzugsweise weniger als 2 W/(mK), bevorzugt weniger als 1 W/(mK), aufweist.
30. 30. Betonfertigteil (1) nach Aspekt 29, dadurch gekennzeichnet, dass das Material der Bewehrung (6) aus einem Material mit geringer Wärmeleitfähigkeit ausgewählt ist aus Kunststoffen, insbesondere aus faserverstärkten Kunststoffen, vorzugsweise aus glasfaser- und/oder karbonfaserverstärkten Kunststoffen.
31. 31. Betonfertigteil (1) nach einem der Aspekte 29 bis 30, dadurch gekennzeichnet, dass die Bewehrung (6) die erste Betonschicht (2) und die zweite Betonschicht (3) verbindet, insbesondere wobei die Bewehrung (6) die Dämmschicht (4) durchdringt.
32. 32. Betonfertigteil (1) nach einem der Aspekte 20 bis 31, dadurch gekennzeichnet, dass das Betonfertigteil (1) eine Bewehrung (7), insbesondere eine zweite Bewehrung, aus einem Metall, insbesondere einem eisenhaltigen Metall, vorzugsweise Stahl, aufweist.
33. 33. Betonfertigteil (1) nach Aspekt 32, dadurch gekennzeichnet, dass die Bewehrung (7) in der zweiten Betonschicht (3) angeordnet ist und gegebenenfalls in einen Hohlraum zwischen der zweiten Betonschicht (3) und der Dämmschicht (4) reicht.
34. 34. Betonfertigteil (1) nach Aspekt 32 oder 33, dadurch gekennzeichnet, dass die Bewehrung (7) in der zweiten Betonschicht (3) und in dem Hohlraum zwischen der zweiten Betonschicht (3) und der Dämmschicht (4) angeordnet ist.
35. 35. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass das Betonfertigteil (1) die Brennbarkeit A1 oder A2 gemäß DIN 4102 aufweist.
36. 36. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die Dämmschicht (4) eine Schichtdicke von 2 bis 30 cm, insbesondere 3 bis 25 cm, vorzugsweise 5 bis 20 cm, bevorzugt 8 bis 15 cm, aufweist.
37. 37. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die erste Betonschicht (2) eine Schichtdicke von 1,5 bis 15 cm, insbesondere 2 bis 12 cm, vorzugsweise 3 bis 10 cm, bevorzugt 4 bis 8 cm, aufweist.
38. 38. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die zweite Betonschicht (3) eine Schichtdicke von 1,5 bis 15 cm, insbesondere 2 bis 12 cm, vorzugsweise 3 bis 10 cm, bevorzugt 4 bis 8 cm, aufweist.
39. 39. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass die Oberfläche der Dämmschicht (4), insbesondere die Oberfläche der Dämmschicht (4) in Kantenbereichen, einer Behandlung zur Festigung der Oberfläche unterzogen wurde.
40. 40. Betonfertigteil (1) nach einem der vorangehenden Aspekte, dadurch gekennzeichnet, dass das Betonfertigteil (1) ein Wandelement und/oder ein Deckenelement ist.
41. 41. Verwendung eines Betonfertigteils nach einem der Aspekte 1 bis 40 zur Erstellung von Bauwerken, insbesondere von Häusern.
42. 42. Baustofftrockenmischung zur Erzeugung einer Dämmmasse zur Herstellung einer Dämmschicht, dadurch gekennzeichnet, dass die Baustofftrockenmischung
    1. (A) ein zementbasiertes Bindemittel in Mengen von 5 bis 50 Gew.-%, bezogen auf die Baustofftrockenmischung,
    2. (B) ein Aerogel in Mengen von 3 bis 50 Gew.-%, bezogen auf die Baustofftrockenmischung, und
    3. (C) mindestens einen Leichtzuschlag in Mengen von 5 bis 60 Gew.-%, bezogen auf die Baustofftrockenmischung,
    aufweist.
43. 43. Baustofftrockenmischung nach Aspekt 42, dadurch gekennzeichnet, dass das zementbasierte Bindemittel Portlandzement, insbesondere Weißzement, vorzugsweise Schnellzement, ist.
44. 44. Baustofftrockenmischung nach Aspekt 42 oder 43, dadurch gekennzeichnet, dass die Baustofftrockenmischung das zementbasierte Bindemittel in Mengen von 10 bis 45 Gew.-%, vorzugsweise 15 bis 40 Gew.-%, bevorzugt 20 bis 30 Gew.-%, bezogen auf die Baustofftrockenmischung, enthält.
45. 45. Baustofftrockenmischung nach einem der Aspekte 42 bis 44, dadurch gekennzeichnet, dass das Aerogel ein Silica-Aerogel und/oder ein Silica-Hybrid-Aerogel ist.
46. 46. Baustofftrockenmischung nach einem der Aspekte 42 bis 45, dadurch gekennzeichnet, dass die Baustofftrockenmischung das Aerogel in Mengen von 5 bis 40_Gew.-%, vorzugsweise 10 bis 35 Gew.-%, bevorzugt 15 bis 30 Gew.-%, bezogen auf die Baustofftrockenmischung, enthält.
47. 47. Baustofftrockenmischung nach einem der Aspekte 42 bis 46, dadurch gekennzeichnet, dass der Leichtzuschlag ausgewählt aus der Gruppe von vulkanischem Gestein, Perlit, insbesondere geblähtem Perlit, Vermiculit, insbesondere geblähtem Vermiculit, Bims, Schaum- und Blähglas, Blähton, Blähschiefer, Tuff, Blähglimmer, Lavakies, Lavasand, und deren Mischungen, vorzugsweise ausgewählt ist aus der Guppe von Perlit, insbesondere geblähtem Perlit, Vermiculit, insbesondere geblähtem Vermiculit, und deren Mischungen.
48. 48. Baustofftrockenmischung nach einem der Aspekte 42 bis 47, dadurch gekennzeichnet, dass die Baustofftrockenmischung den Leichtzuschlag in Mengen von 10 bis 50 Gew.-%, vorzugsweise 15 bis 40 Gew.-%, bevorzugt 20 bis 30 Gew.-%, bezogen auf die Baustofftrockenmischung, enthält.
49. 49. Baustofftrockenmischung nach einem der Aspekte 42 bis 48, dadurch gekennzeichnet, dass die Baustofftrockenmischung ein kalkbasiertes Bindemittel, insbesondere Kalk, vorzugsweise hydraulischen Kalk, aufweist.
50. 50. Baustofftrockenmischung nach Aspekt 49, dadurch gekennzeichnet, dass die Baustofftrockenmischung das kalkbasierte Bindemittel in Mengen von 3 bis 40 Gew.-%, insbesondere 5 bis 30 Gew.-%, vorzugsweise 8 bis 28 Gew.-%, bevorzugt 10 bis 20 Gew.-%, bezogen auf die Baustofftrockenmischung, enthält.
51. 51. Baustofftrockenmischung nach einem der Aspekte 42 bis 50, dadurch gekennzeichnet, dass die Baustofftrockenmischung Fasern, insbesondere anorganische Fasern, vorzugsweise mineralische Fasern, aufweist.
52. 52. Baustofftrockenmischung nach Aspekt 51, dadurch gekennzeichnet, dass die Fasern ausgewählt sind aus Calciumsilikatfasern, Glasfasern, Wollastonitfasern, Kohlenstofffasern, Kohlenstoffnanoröhren und deren Mischungen, vorzugsweise Calciumsilikatfasern.
53. 53. Baustofftrockenmischung nach Aspekt 51 oder 52, dadurch gekennzeichnet, dass die Baustofftrockenmischung die Fasern in Mengen von 0,1 bis 10 Gew.-%, insbesondere 0,5 bis 5 Gew.-%, vorzugsweise 1 bis 4 Gew.-%, bevorzugt 2 bis 4 Gew.-%, bezogen auf die Baustofftrockenmischung, aufweist.
54. 54. Baustofftrockenmischung nach einem der Aspekte 42 bis 53, dadurch gekennzeichnet, dass die Baustofftrockenmischung mindestens einen Porenbildner aufweist.
55. 55. Baustofftrockenmischung nach Aspekt 54, dadurch gekennzeichnet, dass die Baustofftrockenmischung den Porenbildner in Mengen von 0,1 bis 5 Gew.-%, insbesondere 0,5 bis 5 Gew.-%, vorzugsweise 1 bis 4 Gew.-%, bevorzugt 2 bis 4 Gew.-%, bezogen auf die Baustofftrockenmischung, aufweist.
56. 56. Baustofftrockenmischung nach einem der Aspekte 42 bis 53, dadurch gekennzeichnet, dass die Baustofftrockenmischung mindestens ein Additiv aufweist.
57. 57. Baustofftrockenmischung nach Aspekt 56, dadurch gekennzeichnet, dass das Additiv ausgewählt ist aus der Gruppe von Verdickern, Verzögerern, Beschleunigern, Stabilisierungsmitteln (Stabilisatoren), Rheologiestellmitteln, Zusatzmitteln zur Einstellung des Wasserrückhaltevermögens (Wasserretentionsmitteln), Dispergiermitteln, Dichtungsmitteln sowie deren Mischungen.
58. 58. Baustofftrockenmischung nach Aspekt 57, dadurch gekennzeichnet, dass die Baustofftrockenmischung das Additiv in Mengen von 0,01 bis 10 Gew.-%, insbesondere 0,1 bis 5 Gew.-%, vorzugsweise 0,3 bis 3 Gew.-%, bevorzugt 0,5 bis 1 Gew.-%, bezogen auf die Baustofftrockenmischung, enthält.
59. 59. Verwendung einer Baustofftrockenmischung nach einem der Aspekte 41 bis 57 zur Herstellung einer Dämmmasse, insbesondere eines Mörtels.
60. 60. Verwendung nach Aspekt 58, dadurch gekennzeichnet, dass zur Herstellung des Mörtels die Baustofftrockenmischung mit Wasser angemacht wird, insbesondere in einem gewichtsbezogenen Verhältnis von Baustofftrockenmischung zu Wasser von 1 : 0,5 bis 1 : 2, insbesondere 1 : 0,6 bis 1 : 1,8, vorzugsweise 1 : 0,7 bis 1 : 1,6, bevorzugt 1 : 0,8 bis 1 : 1,4.
61. 61. Dämmmasse, insbesondere Mörtel, hergestellt aus einer Baustofftrockenmischung nach einem der Aspekte 42 bis 58 durch Anmachen mit Wasser.

Bezugszeichenliste: 1 Betonfertigteil 5 Hohlraum 2 Erste Betonschicht 6 Erste Bewehrung 3 Zweite Betonschicht 7 Zweite Bewehrung 4 Dämmschicht The invention also relates to the following aspects:

1. 1. Precast concrete part (1), comprising at least one concrete layer (2) and one insulating layer (4), the insulating layer (4) being arranged on the concrete layer,
   characterized,
   that the insulation layer (4) is mineral-based, in particular cement-based.
2. 2. Precast concrete part according to aspect 1, characterized in that the insulating layer (4) is arranged indirectly and / or directly, preferably directly, on the concrete layer (2), in particular is applied to it.
3. 3. Precast concrete part (1) according to aspect 2, characterized in that the insulating layer (4) is arranged on the concrete layer (2) without the use of adhesives and / or mortars.
4. 4. Precast concrete part (1) according to one of the preceding aspects, characterized in that the insulating layer (4) covers at least one surface of the concrete layer (2), in particular at least in some areas, preferably for the most part, preferably almost over the entire surface.
5. 5. Precast concrete part (1) according to one of the preceding aspects, characterized in that the insulating layer (4) is at least 90% by weight, in particular 95% by weight, preferably 97% by weight, preferably 98% by weight, based on the insulation layer (4), consists of inorganic materials.
6. 6. Precast concrete part (1) according to one of the preceding aspects, characterized in that the insulating layer (4) is 90 to 100% by weight, in particular 95 to 100% by weight, preferably 97 to 100% by weight, preferably 98 up to 100% by weight, based on the insulating layer (4), consists of inorganic materials.
7. 7. precast concrete part (1) according to one of the preceding aspects, characterized in that the insulating layer (4) inorganic fillers, in particular mineral fillers, in amounts of at least 20 wt .-%, in particular 40% by weight, preferably 50% by weight, preferably 60% by weight, based on the insulating layer (4).
8. 8. Precast concrete part (1) according to one of the preceding aspects, characterized in that the insulating layer (4) contains inorganic fillers, in particular mineral fillers, in amounts of 20 to 80% by weight, in particular 40 to 75% by weight, preferably 50 to 70 wt .-%, preferably 60 to 70 wt .-%, based on the insulating layer (4).
9. 9. Precast concrete part (1) according to aspect 7 or 8, characterized in that the inorganic fillers selected from the group of volcanic rock, perlite, in particular expanded perlite, vermiculite, in particular expanded vermiculite, pumice, foam and expanded glass, expanded clay, expanded slate, Tuff, expanded mica, lava gravel, lava sand, silica aerogels, silica hybrid aerogels and mixtures thereof, is preferably selected from the group of perlite, in particular expanded perlite, vermiculite, in particular expanded vermiculite, aerogels, in particular silica aerogels and / or silica hybrid aerogels , and mixtures thereof, preferably mixtures thereof.
10. 10. Precast concrete part (1) according to one of the preceding aspects, characterized in that the insulating layer (4) is a lightweight aggregate selected from the group of volcanic rock, perlite, in particular expanded perlite, vermiculite, in particular expanded vermiculite, pumice, foam and expanded glass, Expanded clay, expanded slate, tuff, expanded mica, lava gravel, lava sand and mixtures thereof, preferably selected from the group of perlite, in particular expanded perlite, vermiculite, in particular expanded vermiculite, and mixtures thereof, in combination with an inorganic filler in the form of an airgel, in particular one Silica airgel and / or a silica hybrid airgel.
11. 11. Precast concrete part (1) according to aspect 10, characterized in that the insulating layer (4) has a weight-related ratio of lightweight aggregate to airgel in the range from 15: 1 to 1:10, in particular 10: 1 to 1: 8, preferably 5: 1 up to 1: 5, preferably 2: 1 to 1: 2, particularly preferably 2: 1 to 1: 1.
12. 12. Precast concrete part (1) according to one of the preceding aspects, characterized in that the insulating layer (4) contains fibers, in particular inorganic fibers, preferably mineral fibers.
13. 13. Precast concrete part (1) according to Aspket 12, characterized in that the fibers are selected from calcium silicate fibers, glass fibers, wollastonite fibers, carbon fibers, carbon nanotubes and mixtures thereof, preferably calcium silicate fibers.
14. 14. Precast concrete part (1) according to aspect 12 or 13, characterized in that the insulating layer (4) contains the fibers in amounts of 0.1 to 20% by weight, in particular 0.2 to 15% by weight, in particular 0, 5 to 12% by weight, preferably 1 to 10% by weight, based on the insulating layer (4).
15. 15. Precast concrete part (1) according to one of the preceding aspects, characterized in that the insulating layer (4) has a cement-based binder.
16. 16. Precast concrete part (1) according to one of the preceding aspects, characterized in that the insulating layer (4) has a thermal conductivity in the range from 0.025 to 0.050 W / (mK), in particular 0.030 to 0.045 W / (mK), preferably 0.035 to 0.042 W. / (mK).
17. 17. Precast concrete part (1) according to one of the preceding aspects, characterized in that the insulating layer (4) has a water vapor diffusion resistance number μ, determined according to DIN EN ISO 12542, in the range from 2 to 9, in particular 3 to 7, preferably 4 to 6 .
18. 18. Precast concrete part (1) according to one of the preceding aspects, characterized in that the insulating layer (4) has a dry bulk density in the range from 125 to 250 kg / m ³ , in particular 140 to 225 kg / m ³ , preferably 150 to 200 kg / m ³ , has.
19. 19. Precast concrete part (1) according to one of the preceding aspects, characterized in that the insulating layer (4) has the combustibility A1 or A2 according to DIN 4102.
20. 20. Precast concrete part (1) according to one of the preceding aspects, characterized in that the precast concrete part (1) is a core-insulated prefabricated concrete part.
21. 21. Precast concrete part (1) according to one of the preceding aspects, characterized in that the precast concrete part (1) has a multilayer structure
    1. (I) a first concrete layer (2),
    2. (II) a second layer of concrete (3) and
    3. (III) an insulation layer (4) which is arranged between the first concrete layer (2) and the second concrete layer (3),
    owns,
    characterized,
    that the insulation layer (4) is mineral-based, in particular cement-based.
22. 22. Precast concrete part (1) according to aspect 20 or 21, characterized in that the first concrete layer (2) and the second concrete layer (3) are in particular arranged in parallel at least in some areas.
23. 23. Precast concrete part (1) according to one of aspects 20 to 22, characterized in that the insulating layer (4) is arranged indirectly and / or directly on the first concrete layer (2) and / or the second concrete layer (3).
24. 24. Precast concrete part (1) according to aspect 23, characterized in that the insulating layer (4) is arranged directly on the first concrete layer (2).
25. 25. Precast concrete part (1) according to Aspket 23 or 24, characterized in that the insulating layer (4) is arranged indirectly and / or directly, preferably directly, on the second concrete layer (3).
26. 26. Precast concrete part (1) according to one of aspects 20 to 24, characterized in that the insulating layer (4) and the second concrete layer (3) are spaced apart.
27. 27. Precast concrete part (1) according to aspect 26, characterized in that the insulating layer (4) and the second concrete layer (3) have a distance of 6 to 30 cm, in particular 7 to 20 cm, preferably 8 to 15 cm, preferably 9 to 12 cm.
28. 28. Precast concrete part (1) according to one of the aspects 20 to 27, characterized in that the precast concrete part (1) has at least one reinforcement (6, 7).
29. 29. Precast concrete part (1) according to one of aspects 20 to 28, characterized in that the precast concrete part (1) has reinforcement (6), in particular a first reinforcement, made of a material with low thermal conductivity, in particular with a thermal conductivity of less than 5 W. / (mK), preferably less than 2 W / (mK), preferably less than 1 W / (mK).
30. 30. Precast concrete part (1) according to aspect 29, characterized in that the material of the reinforcement (6) made of a material with low thermal conductivity is selected from plastics, in particular from fiber-reinforced plastics, preferably from glass fiber and / or carbon fiber reinforced plastics.
31. 31. Precast concrete part (1) according to one of aspects 29 to 30, characterized in that the reinforcement (6) connects the first concrete layer (2) and the second concrete layer (3), in particular wherein the reinforcement (6) the insulating layer (4) penetrates.
32. 32. precast concrete part (1) according to one of aspects 20 to 31, characterized in that the precast concrete part (1) has reinforcement (7), in particular a second reinforcement, made of a metal, in particular a ferrous metal, preferably steel.
33. 33. Precast concrete part (1) according to aspect 32, characterized in that the reinforcement (7) is arranged in the second concrete layer (3) and optionally extends into a cavity between the second concrete layer (3) and the insulation layer (4).
34. 34. Precast concrete part (1) according to aspect 32 or 33, characterized in that the reinforcement (7) is arranged in the second concrete layer (3) and in the cavity between the second concrete layer (3) and the insulation layer (4).
35. 35. Precast concrete part (1) according to one of the preceding aspects, characterized in that the precast concrete part (1) has the combustibility A1 or A2 according to DIN 4102.
36. 36. Precast concrete part (1) according to one of the preceding aspects, characterized in that the insulating layer (4) has a layer thickness of 2 to 30 cm, in particular 3 to 25 cm, preferably 5 to 20 cm, preferably 8 to 15 cm.
37. 37. Precast concrete part (1) according to one of the preceding aspects, characterized in that the first concrete layer (2) has a layer thickness of 1.5 to 15 cm, in particular 2 to 12 cm, preferably 3 to 10 cm, preferably 4 to 8 cm, having.
38. 38. Precast concrete part (1) according to one of the preceding aspects, characterized in that the second concrete layer (3) has a layer thickness of 1.5 to 15 cm, in particular 2 to 12 cm, preferably 3 to 10 cm, preferably 4 to 8 cm, having.
39. 39. Precast concrete part (1) according to one of the preceding aspects, characterized in that the surface of the insulating layer (4), in particular the surface of the insulating layer (4) in edge areas, has been subjected to a treatment to strengthen the surface.
40. 40. Precast concrete part (1) according to one of the preceding aspects, characterized in that the precast concrete part (1) is a wall element and / or a ceiling element.
41. 41. Use of a precast concrete part according to one of aspects 1 to 40 for the construction of structures, in particular houses.
42. 42. Dry building material mix for producing an insulating compound for producing an insulating layer, characterized in that the dry building material mix
    1. (A) a cement-based binder in amounts of 5 to 50% by weight, based on the dry building material mix,
    2. (B) an airgel in amounts of 3 to 50% by weight, based on the dry building material mix, and
    3. (C) at least one lightweight aggregate in quantities of 5 to 60% by weight, based on the dry building material mix,
    having.
43. 43. Dry building material mix according to aspect 42, characterized in that the cement-based binder is Portland cement, in particular white cement, preferably quick-release cement.
44. 44. Dry building material mixture according to aspect 42 or 43, characterized in that the dry building material mixture contains the cement-based binder in amounts of 10 to 45% by weight, preferably 15 to 40% by weight, preferably 20 to 30% by weight, based on the Dry building material mix contains.
45. 45. Dry building material mix according to one of aspects 42 to 44, characterized in that the airgel is a silica airgel and / or a silica hybrid airgel.
46. 46. Dry building material mixture according to one of the aspects 42 to 45, characterized in that the dry building material mixture contains the airgel in amounts of 5 to 40% by weight, preferably 10 to 35% by weight, preferably 15 to 30% by weight, based on the Dry building material mix contains.
47. 47. Dry building material mix according to one of aspects 42 to 46, characterized in that the lightweight aggregate is selected from the group of volcanic rock, perlite, in particular expanded perlite, vermiculite, in particular expanded vermiculite, pumice, foam and expanded glass, expanded clay, expanded slate, tuff, Expanded mica, lava gravel, lava sand, and mixtures thereof, is preferably selected from the group of perlite, in particular expanded perlite, vermiculite, in particular expanded vermiculite, and mixtures thereof.
48. 48. Dry building material mixture according to one of aspects 42 to 47, characterized in that the dry building material mixture is based on the lightweight aggregate in amounts of 10 to 50% by weight, preferably 15 to 40% by weight, preferably 20 to 30% by weight the dry building material mix.
49. 49. Dry building material mix according to one of aspects 42 to 48, characterized in that the dry building material mix has a lime-based binder, in particular lime, preferably hydraulic lime.
50. 50. Dry building material mix according to aspect 49, characterized in that the dry building material mix contains the lime-based binder in amounts of 3 to 40% by weight, in particular 5 to 30% by weight, preferably 8 to 28% by weight, preferably 10 to 20% by weight .-%, based on the dry building material mix.
51. 51. Dry building material mix according to one of aspects 42 to 50, characterized in that the dry building material mix has fibers, in particular inorganic fibers, preferably mineral fibers.
52. 52. Dry building material mix according to aspect 51, characterized in that the fibers are selected from calcium silicate fibers, glass fibers, wollastonite fibers, carbon fibers, carbon nanotubes and mixtures thereof, preferably calcium silicate fibers.
53. 53. Dry building material mixture according to aspect 51 or 52, characterized in that the dry building material mixture contains the fibers in amounts of 0.1 to 10% by weight, in particular 0.5 to 5% by weight, preferably 1 to 4% by weight, preferably 2 to 4% by weight, based on the dry building material mixture.
54. 54. Dry building material mix according to one of aspects 42 to 53, characterized in that the dry building material mix has at least one pore former.
55. 55. Dry building material mixture according to aspect 54, characterized in that the dry building material mixture contains the pore former in amounts of 0.1 to 5% by weight, in particular 0.5 to 5% by weight, preferably 1 to 4% by weight, preferably 2 to 4 wt .-%, based on the dry building material mix.
56. 56. Dry building material mix according to one of aspects 42 to 53, characterized in that the dry building material mix has at least one additive.
57. 57. Dry building material mix according to aspect 56, characterized in that the additive is selected from the group of thickeners, retarders, accelerators, stabilizers (stabilizers), rheology control agents, Additives to adjust the water retention capacity (water retention agents), dispersants, sealants and mixtures thereof.
58. 58. Dry building material mixture according to aspect 57, characterized in that the dry building material mixture contains the additive in amounts of 0.01 to 10% by weight, in particular 0.1 to 5% by weight, preferably 0.3 to 3% by weight, preferably 0.5 to 1% by weight, based on the dry building material mix.
59. 59. Use of a dry building material mix according to one of aspects 41 to 57 for producing an insulating compound, in particular a mortar.
60. 60. Use according to aspect 58, characterized in that the dry building material mixture is made up with water to produce the mortar, in particular in a weight-related ratio of dry building material mixture to water of 1: 0.5 to 1: 2, in particular 1: 0.6 to 1 : 1.8, preferably 1: 0.7 to 1: 1.6, preferably 1: 0.8 to 1: 1.4.
61. 61. Insulating compound, in particular mortar, produced from a dry building material mix according to one of aspects 42 to 58 by mixing with water.

<b> List of reference symbols: </b> 1 Precast concrete part 5 cavity 2 First layer of concrete 6th First reinforcement 3 Second layer of concrete 7th Second reinforcement 4th Insulation layer

Claims (15)

Process for the production of a precast concrete part,
characterized,
that (a) in a first process step a hollow form, in particular a formwork, is presented, (b) subsequently, in a second process step, liquid concrete is poured into the hollow form to form a first concrete layer, in particular up to a specified fill level, (c) then, in a third process step following the second process step (b), a mineral-based, in particular cement-based, insulating compound is poured into the hollow form to form an insulating layer, so that a raw insulating element is formed with a concrete layer and an insulating layer, and subsequently the raw insulating element is cured, in particular partially cured, so that an insulating element is obtained. Method according to claim 1, characterized in that
that the raw insulation element is cured at temperatures in the range from 20 to 80 ° C., in particular 30 to 70 ° C., preferably 40 to 60 ° C., and / or
that the raw insulation element is cured for a period of 4 to 20 hours, in particular 5 to 15 hours, preferably 8 to 12 hours. Method according to Claim 1 or 2, characterized in that the raw insulation element is provided with reinforcement, in particular a first reinforcement. Method according to claim 3, characterized in that the reinforcement is presented in the hollow form in the first method step (a) or that the Reinforcement is introduced into the raw insulation element following the third process step (c). Method according to claim 3 or 4, characterized in that the reinforcement is made of a material with low thermal conductivity, in particular with a thermal conductivity of less than 5 W / (mK), preferably less than 2 W / (mK), preferably less than 1 W / (mK), exists. Method according to one of claims 3 to 5, characterized in that the reinforcement extends from the concrete layer into the insulation layer of the raw insulation element, in particular that the reinforcement extends from the concrete layer beyond the insulation layer of the raw insulation element. Method according to one of the preceding claims, characterized in that the insulating element is removed from the hollow form, in particular the formwork. Method according to one of the preceding claims, characterized in that the one further hollow form, in particular formwork, is presented and filled with liquid concrete to form a second concrete layer, in particular it is filled up to a predetermined filling level, so that a second concrete layer is obtained, and then the insulating element is connected with the insulating layer side to the second concrete layer, cohesively or at a distance, preferably at a distance, so that a raw double-layer element, in particular a raw double-wall element, is obtained. Method according to claim 8, characterized in that the raw double-layer element is hardened, in particular partially hardened, preferably at temperatures in the range from 20 to 80 ° C, in particular 30 to 70 ° C, preferably 40 to 80 ° C, so that a double-layer element, in particular a double wall element is obtained. Method according to Claim 9, characterized in that the raw double-layer element is cured for a period of 4 to 20 hours, in particular 5 to 15 hours, preferably 8 to 12 hours. Method according to one of Claims 8 to 10, characterized in that the insulating element is provided with a second reinforcement before it is connected to the second concrete layer or that the further hollow shape is provided with a second reinforcement. Method according to claim 11, characterized in that the second reinforcement consists of a metal, in particular an iron-containing metal, preferably steel. Method according to claim 11 or 12, characterized in that the second reinforcement extends in the second concrete layer and / or that the second reinforcement extends beyond the second concrete layer, in particular into a cavity between the second concrete layer and the insulation layer. A method according to any one of claims 8 to 13, characterized in that the double-layer element is removed from the second hollow mold. Method according to one of the preceding claims for the production of a precast concrete part, characterized in that
that (a) in a first process step a hollow form, in particular a formwork, is presented, (b) subsequently, in a second process step, liquid concrete is poured into the hollow form to form a first concrete layer, in particular up to a specified fill level, and the concrete layer is optionally compacted, (c) then, in a third process step following the second process step (b), a mineral-based, in particular cement-based, insulating compound for forming an insulating layer is poured into the hollow form, so that a raw insulating element is formed with a concrete layer and an insulating layer, and optionally the insulation layer is compacted, (d) in a subsequent fourth process step, the raw insulation element is provided with a first reinforcement, (e) subsequently, in a fifth process step, the raw insulation element is cured, in particular partially cured, so that an insulation element is obtained, (f) if necessary, in a subsequent sixth process step, the insulating element is removed from the hollow mold, (g) if necessary, in a seventh process step, the surface of the insulating layer, in particular the surfaces of the edges of the insulating layer, are subjected to a surface treatment, (h) subsequently, in particular in an eighth process step, the insulating element is provided with a second reinforcement, (i) again subsequently, in particular in a ninth process step, a second hollow form, in particular formwork, is presented, (j) subsequently, in particular in a tenth process step, the second hollow mold is filled up to a predetermined filling level, so that a second concrete layer is formed and, if necessary, the second concrete layer is compacted, (k) subsequently, in particular in an eleventh process step, the insulating element with the insulating layer side is connected to the second concrete layer, in particular via the first reinforcement, so that a raw double-layer element is obtained, (l) subsequently, in particular in a twelfth process step, the raw double-layer element is hardened, in particular partially hardened, so that a double-layer element is obtained, (m) subsequently, in particular in a thirteenth method step, the double-layer element is removed from the second hollow mold and (n) subsequently, in particular in a fourteenth process step, the double-wall element is post-cured.

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